Article packaging system

ABSTRACT

The present invention is a modular system for packaging articles for shipment. In particular, a potted plant is sorted according to a grade, placed in a decorative cover, then automatically deposited into a protective sleeve. The potted plant thus packaged is ready for containment within a shipping carton. Various components of the system may be adapted for various packaging needs and circumstances.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation of U.S. Ser. No.09/866,401, filed May 25, 2001, which is a continuation of U.S. Ser. No.09/785,891, filed Feb. 16, 2001, now U.S. Pat. No. 6,311,461, issuedNov. 6, 2001, which is a continuation of U.S. Ser. No. 09/393,041 filedSep. 8, 1999, now U.S. Pat. No. 6,189,295, issued on Feb. 20, 2001,which is a continuation of U.S. Ser. No. 09/005,630, filed Jan. 9, 1998,now U.S. Pat. No. 6,006,500, issued on Dec. 28, 1999, which is acontinuation of U.S. Ser. No. 08/720,961, filed Oct. 10, 1996, now U.S.Pat. No. 5,706,628, issued on Jan. 13, 1998 which is a continuation ofU.S. Ser. No. 08/462,332, filed on Jun. 5, 1995, now U.S. Pat. No.5,605,029, issued on Feb. 25, 1997 which is a divisional of U.S. Ser.No. 08/417,477, filed Apr. 5, 1995, now U.S. Pat. No. 5,586,425, issuedon Dec. 24, 1996 which is a continuation of U.S. Ser. No. 954,635, filedon Sep. 30, 1992, now abandoned. of U.S. Ser. No. 07/954,635, filed Sep.30, 1992, now abandoned.

FIELD OF THE INVENTION

[0002] The present invention relates generally to a system for packagingarticles for shipment and more particularly, but not by way oflimitation, to a system for automatically packaging potted plants forshipment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003]FIG. 1 is a schematic of an article packaging system constructedin accordance with the present invention.

[0004]FIG. 2 is a plan view of part of the packaging system of FIG. 1showing an automated greenhouse.

[0005]FIG. 3 is a perspective view of a manual sorting station which maybe used in the article packaging system of the present invention.

[0006]FIG. 4 is a plan view of an automatic sorting station which may beused in the article packaging system of the present invention.

[0007]FIG. 5 is an elevational view of a gate constructed in accordancewith the present invention.

[0008]FIG. 6 is a plan view of one embodiment of a cover placing stationwhich may be used with the article packaging system of the presentinvention.

[0009]FIG. 7 is an elevational view of the cover placing station of FIG.6.

[0010]FIG. 8 is an enlarged elevational view of a cover placingsub-unit, in position to retrieve a cover.

[0011]FIG. 9 is the cover placing sub-unit of FIG. 8 in position forreceiving an article.

[0012]FIG. 10 is the cover placing sub-unit of FIG. 8 shown immediatelyafter receiving an article.

[0013]FIG. 11 is an elevational view of another embodiment of the coverplacing sub-unit, constructed in accordance with the present invention.

[0014]FIG. 11A is a plan view of the cover placing sub-unit shown inFIG. 11.

[0015]FIG. 12 is an elevational view of another embodiment of the coverplacing sub-unit, constructed in accordance with the present invention.

[0016]FIG. 12A is a plan view of the cover placing sub-unit shown inFIG. 12.

[0017]FIG. 13 is a plan view of yet another embodiment of the coverplacing sub-unit, constructed in accordance with the present invention.

[0018]FIG. 14 is an elevational view of a sleeve constructed inaccordance with the present invention.

[0019]FIG. 15 is an elevational view of part of a sleeving stationshowing a sleeve before the sleeve is inflated.

[0020]FIG. 16 is a perspective view of part of the sleeving station ofFIG. 15 showing an inflated sleeve.

[0021]FIG. 17 is an elevational view of the sleeving station with partsremoved for clarity.

[0022]FIG. 18 is a plan view of the sleeving station.

[0023]FIG. 19 is a perspective view of the sleeving station and part ofthe sealing station.

[0024]FIG. 20 is an elevational view showing a sealing and a placingstation constructed in accordance with the present invention.

[0025]FIG. 21 is a plan view showing the sealing and placing station ofFIG. 20.

[0026]FIG. 22 is a schematic of another embodiment of an articlepackaging system constructed in accordance with the present invention.

[0027]FIG. 23 is a side view of the packaging system of FIG. 22.

[0028]FIG. 24A is a perspective view of a sleeving station which may beused in an article packaging system of the present invention.

[0029]FIG. 24B is a perspective view of the sleeving station of FIG. 24Aindicating a sleeve positioned to receive a potted plant.

[0030]FIG. 24C is a perspective view of the sleeving station of FIG. 24Aafter the potted plant has been inserted into the sleeve.

[0031]FIG. 24D is a perspective view of the sleeving station of FIG. 24Ashowing the sleeved potted plant pushed onto a conveyor.

[0032]FIG. 25 is a perspective view of a sleeving station modified topush sleeved potted plants directly into a box.

[0033]FIG. 26 is a perspective view of a sleeving station modified totransfer a sleeved potted plant by lifting it into a box.

[0034]FIG. 27A is a perspective view of a sleeving station modified toreceive a pot cover prior to receiving a potted plant.

[0035]FIG. 27B is a perspective view of the sleeving station of FIG. 27Aprepared to receive the potted plant.

[0036]FIG. 28A is an elevational view of a cover supplying device whichmay be used in an article packaging system of the present invention.

[0037]FIG. 28B is a plan view of the cover supplying device of FIG. 28A.

[0038]FIG. 29A is an elevational view of another cover supplying devicewhich may be used in an article packaging system of the presentinvention.

[0039]FIG. 29B is a plan view of the cover supplying device of FIG. 29A.

[0040]FIG. 30A is an elevational view of another cover supplying devicewhich may be used in an article packaging system of the presentinvention.

[0041]FIG. 30B is an elevational view of the device of FIG. 30A after apot cover has been picked up.

[0042]FIG. 30C is a perspective view of the device of FIG. 30A wherein asleeve is readied to receive the pot cover.

[0043]FIG. 30D is a perspective view of the device of FIG. 30A whereinthe pot cover has been inserted into the sleeve.

[0044]FIG. 31 is a plan schematic view of another article packagingsystem of the present invention.

[0045]FIG. 32 is an elevational view of a mobile sleeving station foruse with an article packaging system such as that in FIG. 31.

[0046]FIG. 33 is a plan view of a boxing system for use in an articlepackaging system of the present invention.

[0047]FIG. 34 is a plan view of a portion of another article packagingsystem in which a cover is applied directly to an article by a coverforming apparatus.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] The present invention, an article packaging system, is describedherein as being adapted to process potted plants. However, a pottedplant represents only one article which can be processed with thepresent invention and the present invention specifically contemplatesvarious and numerous other types of articles such as: vases, hats(including cowboy hats, fedoras, caps, derbies, sombreros, fezzes andhelmets), rose stem boxes, flower pots, candy trays, baskets (such asEaster or decorative baskets), corsage boxes, containers, and variousother articles. The term “article” as used herein is intended toencompass all of the specific articles just mentioned and the term“article” also is intended to be broad enough to encompass any otherarticle which may be decorated, sleeved, and then packed for shipping.

[0049] The term “potted plant” as used herein means a botanical item andthe pot, such as a flower pot, within which the botanical item iscontained. The potted plant has potting soil or any other growth mediumor filler, such as foam, known in the art to secure a plant or otherbotanical item within a pot. One end of the botanical item is secured inthe pot and the other end exposed through the opening in the flower pot.The potted plant has an exterior surface comprising the outer surface ofthe pot, about which a decorative cover may be placed or applied.

[0050] The term “botanical item” as used herein means a natural orartificial herbaceous or woody plant, taken singly or in combination.The term “botanical item” also means any portion or portions of naturalor artificial herbaceous or woody plants including stems, leaves,flowers, blossoms, buds, blooms, cones, or roots, taken singly or incombination, or in groupings of such portions such as bouquet or floralgrouping. The term “propagule” as used herein means any structurecapable of being propagated or acting as an agent of reproductionincluding seeds, shoots, stems, runners, tubers, plants, leaves, rootsor spores. The term “growing medium” used herein means any liquid, solidor gaseous material used for plant growth or for the cultivation ofpropagules, including organic and inorganic materials such as soil,humus, perlite, vermiculite, sand, water, and including the nutrients,fertilizers or hormones or combinations thereof required by the plantsor propagules for growth. The term “flower pot” means any type of floralcontainer used to hold a botanical item. Examples of flower pots used inaccordance with the present invention include clay flower pots, plasticflower pots, and flower pots comprised of other natural or syntheticmaterials.

[0051] The present invention particularly contemplates the preparationof potted plants for shipment. More particularly a potted plant may becovered with a formed sheet of decorative material formed into adecorative cover having an interior surface, exterior surface and aninterior space adjacent and surrounded by the interior surface such asthat formed in a mold type article forming system described in detail inU.S. Pat. No. 4,773,182, issued to Weder et al. on Sep. 27, 1988, andwhich is hereby specifically incorporated herein by reference.

[0052] A decorative pattern, such as a color and/or an embossed pattern,and/or other decorative surface ornamentation may be applied to theupper surface and/or the lower surface of the sheet of materialcomprising the decorative cover or portions thereof including, but notlimited to printed design, coatings, colors, flocking or metallicfinishes. The sheet of material comprising the cover also may be opaque,translucent, or totally or partially clear or tinted transparentmaterial.

[0053] The sheet of material may be constructed of a single sheet ofmaterial or a plurality of sheets. Any thickness of the sheet ofmaterial may be utilized in accordance with the present invention aslong as the sheet of material may be wrapped about at least a portion ofa flower pot or deposited within a sleeve, as described herein. Thesheet of material may have a thickness of less than about 1 mil to about30 mils. Typically, the sheet of material has a thickness in a range ofless than about 0.2 mil to about 10 mils. In a preferred embodiment, thesheet of material is constructed from one sheet of man-made organicpolymeric film having a thickness in a range of from less than about 0.5mil to about 2.5 mils.

[0054] The sheet of material is constructed from any suitable materialthat is capable of being wrapped about a flower pot. Preferably, thesheet of material comprises paper (untreated or treated in any manner),cellophane, foil, synthetic organic polymeric film, fiber (woven ornonwoven or synthetic or natural), cloth (woven or nonwoven or naturalor synthetic), burlap, or any combination thereof.

[0055] The term “synthetic organic polymeric film” means a syntheticallymade resin such as a polypropylene as opposed to naturally occurringresins such as cellophane. A synthetic organic polymeric film isrelatively strong and not as subject to tearing (substantiallynon-tearable), as might be the case with paper or foil. The syntheticorganic polymeric film is a substantially linearly linked. Such filmsare synthetic polymers formed or synthesized from monomers. Further, arelatively substantially linearly linked processed organic polymericfilm is virtually waterproof which may be desirable in many applicationsinvolving wrapping botanical items or potted plants.

[0056] Additionally, a relatively thin film of substantially linearlylinked processed organic polymer does not substantially deteriorate insunlight. Processed organic polymeric films having carbon atoms bothlinearly-linked and cross-linked, and some cross-linked polymeric films,also may be suitable for use in the present invention provided suchfilms are substantially flexible and can be made in a sheet-like formatfor wrapping purposes consistent with the present invention. Forexample, one such man-made organic polymeric film is a polypropylenefilm.

[0057] The sheet of material may vary in color. Further, the sheet ofmaterial may consist of designs which are printed, etched, and/orembossed; in addition, the sheet of material may have various colorings,coatings, flocking and/or metallic finishes, or be characterized totallyor partially by pearlescent, translucent, transparent, iridescent, orthe like, characteristics. Each of the above-named characteristics mayoccur alone or in combination. Moreover, each surface of the sheet ofmaterial may vary in the combination of such characteristics.

[0058] The sheet of material has a width extending generally between thefirst side and the second side respectively, sufficiently sized wherebythe sheet of material can be wrapped about and substantially surroundand encompass a flower pot. The sheet of material has a length extendinggenerally between the third side and the fourth side, respectively,sufficiently sized whereby the sheet of material extends over asubstantial portion of the flower pot when the sheet of material hasbeen applied about the flower pot in accordance with the presentinvention shown and described in detail herein.

[0059] The sheet of material may further comprise at least one scent.Examples of scents utilized herein include (but are not limited to)floral scents (flower blossoms, or any portion of a plant), food scents(chocolate, sugar, fruits), herb or spice scents (cinnamon), and thelike. Additional examples of scents include flowers (such as roses,daisies, lilacs), plants (such as fruits, vegetables, grasses, trees),foods (for example, candies, cookies, cake), food condiments (such ashoney, sugar, salt), herbs, spices, woods, roots, and the like, or anycombination of the foregoing. Such scents are known in the art and arecommercially available.

[0060] The scent may be disposed upon the sheet of material by sprayingthe scent thereupon, painting the scent thereupon, brushing the scentthereupon, lacquering the scent thereupon, immersing the sheet ofmaterial to scent-containing gas, or any combination thereof.

[0061] The scent may be contained within a lacquer, or other liquid,before it is disposed upon the sheet of material. The scent may also becontained within a dye, ink, and/or pigment (not shown). Such dyes,inks, and pigments are known in the art, and are commercially available,and may be disposed upon or incorporated in the sheet of material by anymethod described herein or known in the art.

[0062] The decorative cover may be bonded to the article or potted plantby a bonding material. The term “bonding material” as used herein meansan adhesive, preferably a pressure sensitive adhesive, or a cohesive.Where the bonding material is a cohesive, a similar cohesive materialmust be placed on the adjacent surface for bondingly contacting andbondingly engaging with the cohesive material. The term “bondingmaterial” also includes materials which are heat sealable, sonicsealable and, vibratory sealable in these instances, the adjacentportions of the material must be brought into contact and then heat,sound waves or vibrations, respectively, must be applied to effect theseal.

[0063] The term “bonding material” as used herein also means a heatsealing lacquer which may be applied to the sheet of material and, inthis instance, heat also must be applied to effect the sealing. The term“bonding material” as used herein means any type of material or thingwhich can be used to effect the bonding or connecting of the twoadjacent portions of the material or sheet of material to effect theconnection or bonding described herein. The term “bonding material” alsoincludes ties, labels, bands, ribbons, strings, tape, staples orcombinations thereof.

[0064] The decorated article covered with a decorative cover may then beplaced in a sleeve to generally protect it during shipping. For example,a potted plant may be sleeved to preserve water and carbon dioxide forthe plant, and to protect the plant during shipping. The sleeve may bemade from an impermeable material which would retain all gases andliquids or from a semi-permeable material, such as a material whichwould allow oxygen and carbon dioxide to pass, but would inhibit thepassage of water through the material.

[0065] Sleeves are well known in the art of packaging potted plants. Asused herein, a sleeve is cylindrical, conical or frusto-conical in shapeand has an upper opening, which provides an opening for the deposit of apotted plant, or other article, therein. Sleeves may be comprised of anyflexible material suitable for covering a potted plant, includingmaterials selected from a group of materials, comprising paper, metal,foil cloth (natural or synthetic), denim, burlap, or polymeric film, orcombinations thereof. The term polymeric film as used herein means anypolymeric film, including for example, but not by way of limitation,polypropylene film and cellophane. The material comprising the sleevemay be opaque, translucent, or totally or partially transparent and maybe decorated with designs or tints.

[0066] The article, after having been placed in a sleeve, may then beplaced in a container for shipping. The container, such as a box, cartonor crate, may then be sealed and marked for easy identification. Thepresent invention provides an automated line for preparing articles forshipping in the manner just described thereby saving the sellerconsiderable labor expense and reducing the preparation time requiredfor packaging articles.

[0067] In describing the preferred embodiment, a potted plant will beused as an example of the article being processed. However, as discussedabove the invention may be used on various other articles.

Embodiments of FIGS. 1-21

[0068] Turning now to FIG. 1, an article packaging system designated bythe reference numeral 10 is shown which is constructed in accordancewith the present invention. The article packaging system 10 is adaptedto transport an article from a storage location, place a decorativecover over or around the article, place the covered article in a sleeve,and pack the sleeved article in a carton for shipping.

[0069] A storage location such as a greenhouse, hereby designated by thereference numeral 12, supplies potted plants 14 (FIG. 3) for processing.The greenhouse 12 is a frame covered with a material which will allowthe radiant energy from the sun to reach the potted plants 14 which aregrown inside. Such structures are common in the art. Within thegreenhouse 12 are growing racks 16 (FIG. 2) adapted for holding thepotted plants 14 while they are grown. The greenhouse 12 may beautomated by installing conveyors 18 and 20 (also shown in FIG. 2)adapted for transporting the potted plants 14 into and out of thegreenhouse 12. Conveyors 18 and 20 may also serve as additional growingracks. Each conveyor 18 or 20 should be reversible so it may serve tobring potted plants 14 into the greenhouse 12 or supply potted plants 14from the greenhouse 12. Each conveyor 18 or 20 may be similar inconstruction. The construction details of the conveyors 18 and 20 arenot required herein as they are well known to persons of ordinary skillin the art.

[0070] As indicated in FIG. 1, a conveyor 22 extends from the greenhouse12 to a sorting station 24. The sorting station 24 may be a manualsorting station 26 (FIG. 3) or an automatic sorting station 28 (FIG. 4).The manual sorting station 26 comprises a table 30 which receives thepotted plants 14 from the conveyor 22. An operator (not shown) standingnear the table 30 may select the potted plant 14, in accordance with apredetermined grading criterion such as size and grade, and place it ona conveyor 32 or a conveyor 34 with other potted plants (not shown) of asimilar grade. The potted plants 14 are sorted into one of at least twogrades. Conveyors 32 and 34 should begin near the manual sorting station26 and transport the potted plants 14 to the next area for furtherprocessing.

[0071] In an alternative embodiment (not shown), the manual operator atthe manual sorting station 26 may select potted plants 14 directly fromthe conveyor 22 and grade and place them directly from the conveyor 22to conveyors 32 and 34, thereby eliminating the need for the table 30.

[0072] In the automatic sorting station 28 of FIG. 4, the automaticsorting station 28 may be any one several apparatuses for sorting thepotted plants 14. One embodiment of the automatic sorting station 28 isshown in FIG. 4 and comprises a first positioning gate 36 and a secondpositioning gate 38, a light source assembly 40, a light sensor assembly42 which is comprised of at least one sensing device such as aphotoelectric cell 43 and a support backing 44, a light switch 45 and agate 46, all located near the discharge end of the conveyor 22.

[0073] Referring now to FIGS. 4 and 5, the first and second positioninggates 36 and 38 are similar in construction. Each positioning gate 36and 38 has an arm 48 (FIG. 5). The arm 48 is preferably made from astrip of stainless steel about four to eight inches tall and ofsufficient length to reach half way across conveyor 22. One end of thearm 48 is secured as by welding to a rod 50. The rod 50 extends up fromthe arm 48 through a bearing 52, to a motor 54. A collar 56 is securedto the rod 50 above the bearing 52 by a set screw 58, thereby holdingthe arm 48 off the upper surface of the conveyor 22. The bearing 52 issecured to a brace 60 which is mounted to the side of the conveyor 22.

[0074] The first and second positioning gates 36 and 38 are secured toopposite sides of the conveyor 22 and they work in conjunction torelease potted plants 14 at regular intervals. In addition to spacingthe potted plants 14 along the conveyor 22, the first and secondpositioning gates 36 and 38 also position the potted plants 14 generallyin the center of conveyor 22. Therefore, all potted plants 14 arepositioned approximately the same distance from the light sensorassembly 42 as they pass in front of it.

[0075] With continued reference to FIG. 4, the light source assembly 40is comprised of a housing 62 having a slot 64 formed on the sideadjacent the conveyor 22. The housing 62 is secured on one side of theconveyor 22 such that the slot 64 is on the side of the housing 62 whichfaces the conveyor 22. At least one light source 66, such as a lightbulb, is secured within the housing 62 so that light emitted by thelight source 66 passes through the slot 64 and across the conveyor 22.

[0076] Directly across conveyor 22 from the light source assembly 40 isthe light sensor assembly 42.

[0077] The light switch 45 is located in front of the light sourceassembly 40 and turns on the light source 66 when the potted plant 14 isbetween the light source assembly 40 and the light sensor assembly 42.Since the potted plant 14 is between the light source assembly 40 andthe light sensor assembly 42 when the light source 66 is turned on, theamount of light reaching the light sensor assembly 42 depends upon thesize and density of the foliage on the potted plant 14. The taller andmore dense the foliage, the less light reaches light sensor assembly 42.

[0078] The gate 46 is located downstream from the light sensor assembly42 near the end of the conveyor 22. The gate 46 is similar inconstruction to the first positioning gate 36. The brace 60 of gate 46is positioned over the center of the conveyor 22. The gate 46 is pivotedto a first position 68 or a second position 70 depending on the amountof light hitting the light sensor assembly 42. The action of the gate 46is controlled by a control assembly (not shown) which detects the degreeof light detected by the photoelectric cell 43 and responds accordingly.

[0079] While the potted plant 14 is between the light source 66 and thephotoelectric cell 43, the potted plant 14 may be rotated by a rotatingdevice (not shown). In this way light can be sensed and measured atseveral points of rotation of the foliage of the potted plant 14,thereby measuring an average amount of detected light which may providea more accurate grading system for the foliage of the potted plants 14.Alternatively, instead of being rotated, several light readings could bemeasured at several points along the conveyor 22, for example, with thelight readings taken at different angles to the foliage, to derive anaverage of the several readings.

[0080] Directly downstream from the gate 46 is a positioning bar 72. Thepositioning bar 72 is V-shaped and is positioned so the point of the Vis directly downstream from the brace 60 of the gate 46. A first end 74and a second end 76 of the bar 72 extend off a side of the conveyor 22and onto an adjacent conveyor 32 or 34. The first end 74 of the bar 72extends from the conveyor 22 to the conveyor 34. The second end 76 ofthe bar 72 extends from the conveyor 22 to the conveyor 32. Conveyors 32and 34 may lead to similarly constructed processing lines and thus, onlyone such line is described below.

[0081] In an alternative embodiment (not shown), the potted plants 14can be graded on the basis of the difference between a known tare weightof the pot and soil and the weight of potted plant 14. If the tareweight of the pot and saturated soil contained therein is known, thismeasurement can be subtracted from the weight of a potted plant havingsaturated soil. The difference in weight is an approximate measure ofthe weight of the plant. This enables the classification, or grading, ofthe potted plant 14 on the basis of the criterion of weight, rather thanof the basis of the amount of light reaching a light sensor 42, whichrepresents foliage density.

[0082] Other automatic methods of grading the potted plants 14 are touse other forms of electromagnetic radiation such as radar (not shown)or an infra-red light sensing device (not shown) which grades the plantby detecting the amount of heat the plant gives off.

[0083] The embodiment of the article processing system described hereinenvisions only a single sorting station 24 to grade the potted plants14. However, it will be appreciated by one of ordinary skill in the artthat additional sorting stations 24 could be located downstream ofeither conveyor assemblies 32 or 34 to provide additional grading of thepotted plants 14.

[0084] The conveyor 32 moves the potted plants 14 to a covering station82. The covering station 82 may be embodied in a variety of differentforms as described and shown below.

[0085] In the embodiment shown in FIGS. 6 and 7, the covering station 82includes a first gate 84 and a second gate 86, a turnstile 88 and acover denesting sub-unit 90. The first and second gates 84 and 86 aresecured to opposite sides of the conveyor 32 and work in conjunction torelease potted plants 14 at regular intervals. In addition to spacingthe potted plants 14 along the conveyor 32, the first and second gates84 and 86 also position the potted plants 14 in the center of conveyor32. Therefore, all potted plants 14 are positioned to be received by theturnstile 88.

[0086] The turnstile 88 and the cover denesting sub-unit 90 may bemounted on a platform 92 with a plurality of locking casters 94 (FIG.7). Thus, the turnstile 88 and the cover denesting sub-unit 90 may berolled to the side and replaced with a section of conveyor (not shown)when covering the article is not a required step.

[0087] The turnstile 88 has a conduit 98 with a first end 100 and asecond end 102. The first end 100 is secured to the platform 92. Theturnstile 88 has a turnstile axle 104 which has a first end 106 and asecond end 108. The second end 102 of the conduit 98 is open foraccepting the first end 106 of the turnstile axle 104. The diameter ofthe first end 106 of the turnstile axle 104 is slightly smaller than thediameter of the lumen in the conduit 98. This allows the turnstile axle104 to rotate freely within the conduit 98.

[0088] A drive assembly mount 110 is secured near the second end 102 ofthe conduit 98. Secured to the drive assembly mount 110 is a driveassembly 112 with a rotatable shaft 114. Secured to the rotatable shaft114 is a first gear 116. A second gear 118 is secured to the turnstileaxle 104 between the first end 106 and the second end 108 thereof, andin a position such that the first gear 116 and the second gear 118 mesh.

[0089] Secured near the second end 108 of the turnstile axle 104 arefour transfer assemblies 120A, 120B, 120C and 120D. Each transferassembly 120A-120D includes a carrying unit 121, a brace 122, and acylinder 123. The brace 122 has a first end 124 and a second end 125.Each carrying unit 121 comprises a first arm 126 and a second arm 128(FIGS. 6-7).

[0090] The first end 124 of the brace 122 is secured to the turnstileaxle 104 and is adapted for supporting the cylinder 123. The cylinder123 is secured to the second end 125 of the brace 122.

[0091] Secured to the cylinder 123 are the first and second arms 126 and128 of the carrying unit 121. The cylinder 123 is adapted toreciprocatingly raise and lower the carrying unit 121.

[0092] Referring now to FIGS. 6-10, also secured to the platform 92 isan automatic cover supplying assembly, also referred to as the coverdenesting sub-unit 90. The cover denesting sub-unit 90 includes a coverdispenser housing 130 and a cover dispenser support 132 (FIGS. 8-10)having a base 133. The cover dispenser support 132 is adapted forsupporting the cover dispenser housing 130 over the platform 92. Thecover denesting sub-unit 90 also includes a conveyor with a firstparallel belt 134 and a second parallel belt 136. The first and secondparallel belts 134 and 136 are placed around rollers 138 and 140 (FIG.7), and are spaced apart to provide a gap 142 lengthwise for enablingthe placement of a retrieved cover into a potted plant applicationposition.

[0093] A conveyor 144 having a first end 146 and a second end 148 (FIG.19) is abutted at its first end 146 to the end of the belts 134 and 136in a position to receive a cover 158 or a covered potted plant frombelts 134 and 136.

[0094] A suction support arm 150 is generally L-shaped and is pivotallysecured at a first end 151 near the base 133 of the cover dispensersupport 132. The suction support arm 150 has a free end 153.

[0095] A cylinder 152 extends between the platform 92 and the suctionsupport arm 150 and is slidingly secured to the suction support arm 150by a bracket 154. The cylinder 152 and bracket 154 are adapted forraising the suction support arm 150 so a suction cup 156, which isconnected to the free end 153 (FIG. 8) of the suction support arm 150,is raised to a position for removing the cover 158 (FIGS. 8-10) from thecover dispenser housing 130.

[0096] Secured to the platform 92 directly below the suction support arm150 is a vacuum valve 160 and a support spring 162. A vacuum line 164extends from the suction cup 156 to the vacuum valve 160 and on to avacuum source (not shown). Operational details of the cover denestingsubunit 90 are described below in the In Operation section.

[0097] An alternate cover denesting sub-unit (automatic cover supplyingassembly) embodiment, herein designated by the reference numeral 90A, isshown in FIGS. 11-11A. This embodiment uses an article forming system165, such as is disclosed in U.S. Pat. No. 4,773,182, the specificationof which is hereby incorporated herein by reference. The article formingsystem 165 places covers on a suction cup 156A. The suction cup 156A issupported by a rod 166 which extends up between a first parallel belt134A and a second parallel belt 136A in a fashion similar to the suctionsupport arm 150 described above. This embodiment also includes a vacuumvalve 160A and a support spring 162A.

[0098] Another cover denesting sub-unit embodiment, herein designated bythe reference numeral 90B, is shown in FIGS. 12 and 12A. In thisembodiment, the article forming system 165 places a cover (not shown) ona table 168, and a turnstile (not shown), then places a potted plant(not shown) into the cover (not shown). Alternatively, a potted plantmay be placed manually within the cover. A pusher assembly 170 comprisedof a cylinder 171 and a pushing arm 172 then pushes the covered pottedplant (not shown) onto the conveyor 144.

[0099] Another cover denesting sub-unit embodiment, herein designated bythe reference numeral 90C, is shown in FIG. 13. The cover denestingsubunit 90C uses a first gate 174 and a second gate 176 to hold a cover(not shown) stationary on the moving conveyor 144. Once the potted plant(not shown) is in the cover (not shown), the first and second gates 174and 176 open, allowing the covered potted plant (not shown) to proceeddown conveyor 144 for further processing.

[0100] At some point after the cover 158 has been denested andpositioned, a potted plant 14 is placed into the interior space of thecover 158 producing a covered potted plant 180 (FIG. 7). The pottedplant 14 may be placed into the cover 158 manually or automatically. Thecovered potted plant 180 is conveyed down conveyor 144 toward the secondend 148, where it is transferred to an automatic sleeving station 184for application of a sleeve about the covered potted plant 180 to form asleeved covered potted plant.

[0101] Referring now to FIGS. 1 and 17-19, the sleeving station 184includes a guiding assembly comprising a first spring-loaded guide 186and a second spring-loaded guide 188. The first and second spring-loadedguides 186 and 188 (FIG. 18) receive the covered potted plant 180 as itmoves from the second end 148 of the conveyor 144. A brace 190 issecured above the first and second spring-loaded guides 186 and 188 tokeep the potted plant 180 upright as it moves in direction 192 (FIG. 17)through the first and second spring-loaded guides 186 and 188. Below thefirst and second spring-loaded guides 186 and 188 are a first wicket 194and a second wicket 196 for holding a plurality of sleeves, such as asleeve 198 (FIGS. 14-16) and described in detail below. Each wicket 194and 196 has a first end 200 and a second end 202 (FIG. 19). The firstend 200 is secured to a brace (not shown) and extends downwardly at anangle to a point 206 between the first end 200 and the second end 202.From the point 206 to the second end 202, the wickets 194 and 196 extendhorizontally or slightly downward.

[0102] As is shown in FIGS. 14-16, each sleeve 198 has a front side 208having a height 210, and a back side 212 having a height 214. The height210 of the front side 208 of the sleeve 198 is less than the height 214of the back side 212 of the sleeve 198. Holes 216 and 218 are formed inthe upper corners of the back side 212 of each sleeve 198. Although thesleeve 198 is shown in FIGS. 14-17 as tubular, the shape of the sleeve198 may be any variety of shapes but the preferred embodiment isfrusto-conical. Additionally, in an alternative embodiment, heights 210and 214 may be the same and the holes 216 and 218 may extend throughboth the front and back sides 208 and 212 of each sleeve 198.

[0103] Referring now in particular to FIGS. 15 and 16, the first andsecond wickets 194 and 196 extend through the holes 216 and 218,respectively, to support the sleeve 198. The wickets 194 and 196 aresecured so that the sleeve 198 is pulled by gravity down the wickets 194and 196 until the backside 212 of the sleeve 198 comes into contact withan automatic sleeve opening assembly comprising an inflator tube 220(FIG. 16). Air exiting the inflator tube 220 opens and inflates thesleeve 198.

[0104] In an alternative embodiment of the sleeve opening assembly,suction cups (not shown) may be employed to pull open the front side 208of the sleeve 198 to allow the air blast from the inflator tube 220 andto more easily access and open the sleeve 198.

[0105] As the covered potted plant 180 reaches the end 148 of theconveyor 144 and moves in direction 192 through the chute between thefirst and second spring-loaded guides 186 and 188 and the brace 190, itis deposited into the open sleeve 198 (FIG. 19) to provide a sleevedpotted plant 222 (also referred to in this instance as a sleeved coveredpotted plant).

[0106] In an alternative embodiment (not shown), the covered pottedplant 180 may be formed into the sleeved covered potted plant 222 bywrapping a sheet of sleeving material (not shown) about the coveredpotted plant automatically.

[0107] Referring now to FIGS. 1, 20 and 21, a gripping station 230, alsoreferred to as a transfer station, is positioned to remove the sleevedpotted plant 222 from the wickets 194 and 196. The gripping station 230comprises a turnstile 234, a first gripping arm 236 and a secondgripping arm 238. The turnstile 234 further comprises a conduit 240 witha first end 242 and a second end 244. The first end 242 of the conduit240 is secured to a base 246. The second end 244 of the conduit 240 isopen for accepting a first end (not shown) of a turnstile axle 250. Theturnstile axle 250 has a first end (placed inside the conduit 240) and asecond end 254. The diameter of the turnstile axle 250 is slightlysmaller than the diameter of the opening in the conduit 240. This allowsthe turnstile axle 250 to rotate freely within the conduit 240.

[0108] A drive assembly bracket 256 is secured near the second end 244of the conduit 240. Secured to the drive assembly bracket 256 is a driveassembly 258, such as a motor. The drive assembly 258 has a rotatableshaft 260. Secured to the rotatable shaft 260 is a first gear 262. Asecond gear 264 is secured to the turnstile axle 250 in a position suchthat the teeth on the first gear 262 mesh with teeth of the second gear264.

[0109] Secured to the second end 254 of the turnstile axle 250 aresupport arms 266A, 266B, 266C and 266D. Each support arm 266A-266Dincludes the first gripping arm 236 and the second gripping arm 238.Connected to each support arm 266A-266D is a cylinder 270 adapted forclosing the first gripping arm 236 and the second gripping arm 238together against the upper end of the sleeve 198 of the sleeved pottedplant 222.

[0110] In an alternative embodiment, the first gripping arm 236 includesa heating element (not shown) adapted to seal the upper end of thesleeve 198 of the sleeved potted plant 222 when the upper end iscompressed between the gripping arms 236 and 238 thereby forming asealed sleeved potted plant 272. The gripping arms 236 and 238 grasp thesealed sleeved potted plant 272, thereby freeing the sealed sleevedpotted plant 272 from the wickets 194 and 196. From there, the supportarm 266 carries the sealed sleeved potted plant 272 to a placing station274 (FIGS. 1, 20-21). The upper portion of the sleeve 198 mayalternately be sealed by gripping arms 236 and 238 which comprise sonicelements, vibratory elements or pressure-sensitive elements.

[0111] Positioned to receive the sleeved potted plant 222 or the sealedsleeved potted plant 272 is the placing station 274 (FIGS. 20-21). Theplacing station 274 comprises a lowering arm 276, a first pinching arm278, a second pinching arm 280 and a cylinder 282.

[0112] The lowering arm 276 is reciprocatingly secured to the cylinder282 such that the lowering arm 276 may be reciprocatingly lowered andraised. The first pinching arm 278 is pivotally secured opposite thepinching arm 280 of the lowering arm 276. The pinching arms 278 and 280first receive the sleeved potted plant 222 or the sealed sleeved pottedplant 272 at a receiving position 284 (FIG. 21). A small cylinder 288 issecured between the lowering arm 276 and the first pinching arm 278. Thecylinder 288 is adapted to allow the pinching arms 278 and 280 to graspand release the sealed sleeved potted plant 272 or the sleeved pottedplant 222.

[0113] The cylinder 282 is suspended from a rail 290. The rail 290 has afirst end 292 and a second end 294. Secured to the first end 292 of therail 290 is a motor 296 with rotatable shaft 298. Secured to therotatable shaft 298 is a sprocket 300. On the second end 294 of the rail290 is an idler sprocket 302. A continuous loop of chain 304 extendsaround the first sprocket 300 and the second sprocket 302. The cylinder282 is secured to the chain 304 so that upon rotating the shaft 298, thecylinder 282 is moved along the rail 290 to a predetermined position forlowering the grasped sleeved potted plant 222 or the sealed sleevedpotted plant 272 into a box or carton 306.

[0114] A carton placing conveyor 308 is adapted to move the carton 306into position for receiving the sleeved potted plant 222 or the sealedsleeve potted plant 272. Once the carton 306 is full the conveyor 308removes the carton 306 from the packing area. Cartons, like carton 306,are supplied from a carton folding station 310 (FIG. 1). Manycommercially available carton folders are suitable, and therefore, neednot be described herein. Alternatively, cartons 306 may be suppliedmanually.

[0115] In Operation

[0116] Articles 14, which may be potted plants as shown, for example inFIG. 3, are placed on the conveyor 22, then are moved to the sortingstation 24 (FIG. 1). If the sorting station 24 is a manual sortingstation 26, such as shown in FIG. 3, an operator (not shown) will selectarticles 14 to be packaged together, and place them on the conveyor 32or 34, which will carry the articles 14 to the next station.

[0117] If the sorting station 24 is the automatic sorting station 28,such as shown in FIG. 4, the articles 14 will travel down conveyor 22until they come in contact with positioning gates 36 and 38. Thepositioning gates 36 and 38 will hold an article 14 until apredetermined distance 312 between the article 14 and a previous article14 a has been achieved. Once the distance 316 between the article 14 andthe previous article 14 a has been achieved, positioning gates 36 and 38will open allowing the article 14 to proceed on to the light sensorassembly 42.

[0118] Since the positioning gates 36 and 38 open simultaneously, thearticle 14 will be centered on the conveyor 22, and thus, all articles14 will be the same distance from the light sensor assembly 42 as theypass in front of it. As the article 14 passes in front of the lightsensor assembly 42, the article 14 comes into contact with and moves thelight switch 45. Movement of the light switch 45 activates the lightsource 66 in the housing 62.

[0119] Light leaving the housing 62 through the slot 64 will bepartially absorbed and partially reflected by the article 14. Thus, thelarger and more dense the article 14, the less light will reach thephotoelectric cell 43. In this way, smaller or less dense articles 14may be distinguished from larger or denser articles 14. If the article14 is small, the gate 46 will swing into the first position 68 and ifthe article 14 is large, the gate 46 will swing into the second position70, as determined by a control assembly (not shown). As the article 14comes into contact with the gate 46, it is directed to one side of thepositioning bar 72. The positioning bar 72 further directs the article14 onto an adjacent conveyor, such as conveyor 32. Alternately, thearticle 14 may be sorted after a decorative cover has been applied.

[0120] If the article 14 is to receive a decorative cover, which in thecase of a potted plant would be a flower pot cover, the covering station82 will be positioned at the end of the conveyor 32. The articlecovering station 82 is mounted on the platform 92 with the lockingcasters 94. Thus, if no covering is required, the covering station 82may simply be rolled to the side and a section of conveyor (not shown)may take its place. Assuming that covering is desired, any of theseveral embodiments may be used with ease.

[0121] In the preferred operational embodiment, the article 14 willfirst encounter the first and second gates 84 and 86 (FIGS. 6-7). Thefirst and second gates 84 and 86 hold the article 14 until the turnstile88 is in position to accept the article 14, that is, when transferassembly 120A is in line with conveyor 32. As soon as the article 14 hasentered the arms 126 and 128 of the carrying unit 121, the carrying unit121 is raised by the cylinder 123 and the turnstile 88 begins to turn ina counterclockwise direction 314 (FIG. 6).

[0122] When the transfer assembly 120A is in a position 316 (FIG. 6),the suction support arm 150 is raised by the cylinder 152 (see FIG. 8).By the time the transfer assembly 120A has reached a position 318, thesuction support arm 150 has been lowered by the cylinder 152, suctionlybringing with it the cover 158 from the cover dispensing housing 130(see FIG. 9). When the transfer assembly 120A reaches a position 320(FIG. 6), the turnstile 88 momentarily stops over the cover 158 whilethe cylinder 124 lowers the carrying unit 121, thereby lowering thearticle 14 into the cover 158. The weight of the article 14 and cover158 depress the support spring 162, thus lowering the covered article180 onto conveyor belts 134 and 136 (see FIG. 10).

[0123] As the support spring 162 is depressed, the vacuum valve 160 isdeactivated, thereby causing the suction cup 156 to release the cover158 and allowing the covered article 180 to rest upon the conveyor belts134 and 136. The conveyor belts 134 and 136 direct the covered article180 toward conveyor 144 (FIG. 7), and thus out of the carrying unit 121.As the turnstile 88 resumes rotation, and as the transfer assembly 120Apasses through a position 322 (FIG. 6), cylinder 124 retracts thecarrying unit 121, thereby raising the first arm 126 and the second arm128 of the carrying unit 121 into position for receiving the nextarticle 14 from the conveyor 32.

[0124] The covered article 180 is directed from the first and secondparallel belts 134 and 136 to the conveyor 144 (FIG. 7), and continuesto the sleeving station 184 (FIG. 17). As the covered article 180reaches the second end 148 of the conveyor 144, it drops gravitationallythrough the pair of spring-loaded guides 186 and 188 (FIG. 18). Thebrace 190 supports the upper side of the covered article 180 as it dropsfrom the conveyor 144 thereby maintaining the vertical positioning ofthe covered article 180 as it drops. The spring-loaded guides 186 and188 guide the covered article 180 into the opened sleeve 198 (FIG. 19).

[0125] As is shown in FIG. 16, a supply of sleeves 198 is supported onwickets 194 and 196, and are gravitationally fed to the inflator tube220. The end of the inflator tube 220 comes into contact with the backside 212 (FIG. 16) of the first sleeve 198 in the supply, thus keepingthe supply of sleeves 198 from sliding down the wickets 194 and 196. Airexiting from the inflator tube 220 inflates the lowermost sleeve 198 inpreparation for receiving a covered article 180. The added weight of thecovered article 180 dropping from the conveyor 144 causes the openedsleeve 198 to sag, thus releasing it from the inflator tube 220 andenabling it to slide down wickets 194 and 196 to the horizontal sectionof the wickets 194 and 196 (FIG. 19). After the first sleeve 198 isremoved another sleeve 198 moves into position to be inflated. The firstsleeve 198 containing the covered article 180, now constituting asleeved covered article 222, is grasped by first and second grippingarms 236 and 238 (FIG. 19) of the gripping (transfer) station 230 (FIGS.20 and 21).

[0126] The turnstile 234 then rotates, thus pulling the sleeve 198 fromthe wicket 194 and 196. In one embodiment, as the turnstile 234continues to rotate, heating elements (not shown) in the first grippingarm 236 heat the gripped portions of the sleeve 198, sealing the frontand the back sides 208 and 212, respectively, of the sleeve 198 of thesleeved covered article 222 (FIG. 21) to form the sealed sleeved coveredarticle 272. In one version, the sleeve 198 is not sealed over thesleeved covered article 222. As the turnstile 234 rotates 180 degrees tothe receiving position 284, the first and second gripping arms 236 and238, still carrying the sleeved covered article 222 or the sealedsleeved article 272 (as the case may be), move between the firstpinching arm 278 and the second pinching arm 280 of the placing station274 (FIGS. 20-21).

[0127] Once the first and second gripping arms 236 and 238 are betweenthe first pinching arm 278 and the second pinching arm 280, the firstand second pinching arms 278 and 280 close to pinch the sleeve 148 ofthe sleeved covered article 222 or of the sealed sleeved covered article272 (as the case may be) and the first and second gripping arms 236 and238 are opened slightly. Thus, the sleeved potted plant 222 or thesealed sleeve potted plant 272 is now held by the first and secondpinching arms 278 and 280 of the placing station 274. Immediatelythereafter, the cylinder 282 is pulled along the rail 290 via the motor296 and chain 304 (FIGS. 20-21) from the receiving position 284 to theposition 326 and the sleeved potted plant 222 or the sealed sleevedpotted plant 272 is lowered into the carton 306. The first and secondpinching arms 278 and 280 are then released and the lowering arm 276 israised and returned to the receiving position 284 to accept the nextsleeved potted plant 222 or sealed sleeved potted plant 272.

[0128] Each sleeved potted plant 222 or sealed sleeved potted plant 272is received and placed in the carton 306. Placing of the article 222 or272 in the carton 306 may be manually or automatically controlled(control mechanism not shown). The conveyor 308 moves as necessary toallow placing of the sleeved potted plant 222 or the sealed sleevedpotted plant 272 in the carton 306.

[0129] This cycle repeats until the carton 306 is full. At that time,conveyor 308 carries away the full carton 306 and replaces it with a newcontainer 306. The full carton 306 eventually reaches a carton closingstation 330 (FIG. 1) and then a carton labeling station 332 (FIG. 1),where machines of construction well known to those of ordinary skill inthe art close and label the carton 306. The carton 306 is then ready forshipment.

Embodiments of FIGS. 22-34

[0130] Attention is now directed to an article packaging systemdesignated by the reference numeral 350 and represented in FIGS. 22 and23. The article packaging system 350 is a processing line for sortingarticles, for example in this case potted plants 352, according to size,quality, or other criteria and then for processing and packaging theprocessed plants. The article packaging system 350 automatically placesa covered potted plant into a protective sleeve and then places thesleeved pot into a box or carton for shipping and distribution.

[0131] In overview, the article packaging system 350 comprises a servicestation 356 having a platform or table 358 serving to support a set ofunsorted potted plants 352. A sorting station 360 employs a sorter whichinspects the potted plants 352 and sorts them in accordance withpredetermined criteria such as size, quality or variety or any number ofother criteria. The sorting station 360 may be manually operated likethe sorting station 26 described herein or it may operate automatically,for example, like the automatic sorting station 28 described herein.

[0132] A cover supplying station 362 comprises an automatic coversupplying assembly 364 (FIGS. 28A-B) for selecting a pot cover 366 andplacing the pot cover 366 in an application position for receiving thepotted plant 352, thereby forming a covered potted plant 368. Thecovered potted plant 368 is then placed on a conveyor 370.

[0133] A sleeving station 372, constructed much the same as the sleevingstation 184 described herein, is downstream of the conveyor 370 andcomprises an apparatus for applying a protective sleeve 374 to thecovered potted plant 368 to form a sleeved covered potted plant 376. Thesleeved covered potted plant 376 is placed onto a conveyor 378 forfurther processing. A gate station 380 is a gate 382 which serves todivert the sleeved covered potted plants 376 to a separate first lane383 and a separate second lane 384 of the conveyor 378 in preparationfor being placed in a carton. A gathering station 386 is a first gate388 and a second gate 390 for stopping and accumulating the sleevedcovered potted plants 376 in preparation for boxing. In an alternativeembodiment, either the gate station 380 or the gathering station 386, orboth the gate station 380 and the gathering station 386, are optional.

[0134] A carton feeding station 394 comprises a conveyor 396 forconveying or feeding in direction 398 boxes or cartons 400 which willreceive the sleeved covered potted plants 376. A boxing station 404pushes or conveys the sleeved covered potted plants 376 into an emptycarton 400 for shipping. A closing station 408, if present, serves toclose and secure by taping, gluing or stapling each full carton 402 inpreparation for shipping. The closing station 408 could be automatic orcould be manually operated. All stations from the cover supplyingstation 362 to the closing station 408, inclusive, comprise a singleprocessing stream of the article packaging system 350. The articlepackaging system 350 may comprise a second processing stream 412 forprocessing other potted plants sorted at the sorting station 360.

Embodiments of Cover Supplying Stations

[0135] Turning now to FIGS. 28A-28B, the apparatus comprising the coversupplying station 362 is described in more detail. The cover supplyingassembly 364 is an apparatus having a denesting arm 416 for denesting apot cover 366 from a bin 418 and transferring the pot cover 366 to areceiving position 420 for receiving a potted plant 422. The denestingarm 416 has a grasping end 424 and a pivoting end 426. The grasping end424 has a shape adapted to fit around a base 428 of one of the potcovers 366 resting in the bin 418 of pot covers 366. The grasping end424 grasps the base 428 of the pot cover 366, in the preferredembodiment by a suctioning mechanism 430 and disengages the pot cover366 from the bin 418 of pot covers 366. The arm 416, now carrying a potcover 366, pivots in direction 432 to a position over the conveyor 370.The suction from the suctioning mechanism 430 is removed, therebyreleasing the pot cover 366 and placing the pot cover 366 on theconveyor 370 in preparation for receiving the potted plant 422. Theconveyor 370 may be equipped with guide walls 434 to guide the pot cover366 to a gate 436 to restrain the pot cover 366 in a stationaryposition. At this position, the potted plant 422 is disposed within thepot cover 366 to form the covered potted plant 368.

[0136] The gate 436 is opened. The covered potted plant 368 is releasedtherefrom and travels in direction 438 down the conveyor 370 to the nextstation. Meanwhile, the denesting arm 416 is pivoted away in direction440 and is returned to a position to retrieve the next pot cover 366.

[0137] Another denesting embodiment of the cover supplying station 362,illustrated in FIGS. 29A-29B, comprises a cover supplying assembly 364 ahaving a denesting arm 416 a for denesting one of the pot covers 366from the bin 418 and transferring the pot cover 366 to a receivingposition 420 a for receiving the potted plant 422. In this embodiment,the grasping end 424 a of the arm 416 a comprises a suction cup 424 awhich places a suction on an outer bottom 442 of the base 428 of the potcover 366. The denesting arm 416 a pivots away from the bin 418, and thepot cover 366 is removed from the bin 418 and carried to a conveyorassembly 444.

[0138] The conveyor assembly 444 comprises a first parallel belt 446 anda second parallel belt 448 having a gap 450 extending lengthwisetherebetween. The grasping end 424 a with the suction cup 424 a isdisposed in the gap 450 between the parallel belts 446 and 448 of theconveyor assembly 444. As the bottom 442 of the pot cover 366 approachesthe conveyor assembly 444, the suction from the suction cup 424 a isreleased and, as the grasping arm 424 a continues its downward motion,the pot cover 366 is rested gently on the conveyor assembly 444 and iscarried by the parallel belts 446 and 448 in direction 452 through theguide walls 434 to the gate 436.

[0139] At the gate 436, the pot cover 366 is held stationary while thepotted plant 422 is disposed manually or automatically within the potcover 366, thereby providing the covered potted plant 368. The denestingarm 416 a is then available to retrieve another pot cover 366. The coversupplying assemblies 364 and 364 a may be equipped with sensors (notshown) to regulate and control the operation of the denesting arms 416and 416 a and of the conveyor assemblies 370 and 444 and gates 436.

Embodiments of Sleeving Stations

[0140] Turning now to FIGS. 24A-D, a sleeving apparatus 460 of thesleeving station 372 will be described. The sleeving apparatus 460comprises a sleeve support assembly comprising a first wicket 462 and asecond wicket 464 which bear a set of sleeves 466. The sleevingapparatus 460 is the same as a sleeving station 484 described hereinexcept for the modifications described herein. Each wicket 462 and 464extends horizontally for a distance, then bends downward diagonally. Thesleeving apparatus 460 further comprises a suctioning tube 468 whichapplies a suction to a first side 470 of one of the sleeves 466 forloosening and separating the first side 470 from a second side 472 ofthe sleeve 466 to provide an opening 474 at the upper end of the sleeve466 (FIGS. 24A, 24B and 24D).

[0141] Air is forced into the opening 474 of the sleeve 466 from aninflator tube 476 and the sleeve 466 is thereby sufficiently inflated toreceive the covered potted plant 368. The inflator tube 476 is retractedby an inflator cylinder 477 or by another retracting device (FIG. 24B).One of the covered potted plants 368 is then deposited into the opensleeve 466. The covered potted plant 368 may be automatically depositedin the sleeve 466 via a mechanism similar to that shown in FIGS. 17-18for the sleeving station 184 described previously. Alternatively, thecovered potted plant 368 may be deposited into the sleeve 466 manuallyby an operator. Alternatively, the potted plant 422 without the cover366 may be inserted into the sleeve 466, thereby by passing the coversupplying assembly 364.

[0142] The suction tube 468 is then retracted into a suction cylinder478. A resulting sleeved covered potted plant 480 will then slide, viagravity, down the wickets 462 and 464 in direction 482 to a position 483over the conveyor 378 (FIG. 24C). The sleeved covered potted plant 480may slide onto the conveyor 378 and, by the friction of the conveyor 378underneath the bottom 442 of the base 428 of the sleeved covered pottedplant 480, be carried by the conveyor 378 away from the sleeving station372.

[0143] Alternatively, the sleeving apparatus 460 may be equipped with adisengaging assembly comprising an extendable pushing arm 486 to pushthe sleeved covered potted plant 480 in direction 485 off the wickets462 and 464 onto the conveyor 378 (FIG. 24D). The sleeved covered pottedplant 480 is thereby conveyed upon the conveyor 378 downstream and isultimately packed into the carton 400. The extendable pushing arm 486 isthen retracted by a pushing arm cylinder 488 in preparation for the nextsleeved covered potted plant 480. Operation of the sleeving station 372may be regulated by sensing devices (not shown) opening the sleeve 466in preparation for depositing a potted plant therein and for maintainingan even and regulated flow of sleeved covered potted plants 480 on theconveyor 378.

[0144] The components of the sleeving apparatus embodiments areillustrated in FIGS. 15-19 and 24A-27B as isolated. However, it will beappreciated and understood by one skilled in the art that the componentscould be easily and completely attached and assembled together to form aunified apparatus.

Embodiments of the Boxing Stations

[0145] Referring now to FIGS. 25-26, the sleeved covered potted plants480 may be boxed at the boxing station 404 immediately after leaving thesleeving station 372. In one embodiment, the boxing station 404comprises a boxing assembly 500 and an extendable automatic pushing arm502 which, while pushing the sleeved covered potted plant 480 off thewickets 462 and 464, proceeds to push the sleeved covered potted plant480 in direction 504 into the open-sided box or carton 400 resting on anadjacent conveying system 506 (FIG. 25). Once the carton 400 is filled,the filled carton 402 (FIG. 22) is passed to the closing station 408 forclosing and securing. The pushing arm 502 is retracted by a retractingcylinder 508 in preparation for another sleeved covered potted plant480.

[0146] In another embodiment of the boxing station 404 (FIG. 26), aboxing assembly 510 has a pivotable automatic gripping arm 512 having agripping end 514. The gripping end 514 of the gripping arm 512 grips anupper portion 516 of the sleeved covered potted plant 480. The grippingarm 512 is retractable by a cylinder 518 attached to a pivoting brace520. The pivoting brace 520 is pivoted in direction 522 to a positionover a carton 400 a having an open upper side and the gripping arm 512lowers the sleeved covered potted plant 480 into the carton 400 a. Thecarton 400 a can then be closed and secured for shipping. Alternatively,rather than having the gripper arm 512 move the sleeved covered pottedplant 480 to a specific location in the carton 400 a, the gripper arm512 may only lift the sleeved covered potted plant 480 and the carton400 a may be automatically moved beneath the lifted sleeved coveredpotted plant 480 to be properly positioned to accept the sleeved coveredpotted plant 480 lowered thereinto.

[0147] Another embodiment of a boxing assembly is designated by thereference numeral 530 and is shown in FIG. 33. Sleeved covered pottedplants 480 are individually directed into the open-sided carton 400 witha pushing arm 532 in direction 534. Sensors (not shown) detect thepositions of the sleeved covered potted plants 480 already within thecarton 400 and regulate the action of the pushing arm 532. Once thecarton 400 is filled, the carton 400 is closed and secured and moved indirection 536 on the conveyor 396 for shipping. The empty open-sidedcarton 400 is delivered as a replacement, in one embodiment by anautomatic boxing delivery assembly. The extendable pushing arm 532 isindicated in FIG. 33 as being driven by a cylinder 538 but it isunderstood by one of ordinary skill in the art that there are othermechanisms for causing the advancement and retraction of the pushing arm532.

Preinsertion of Cover into Sleeve

[0148] Turning now to FIGS. 27A-B and 30A-D, instead of the potted plant422 being covered by one of the pot covers 366 prior to insertion intothe sleeve 466, the pot cover 366 may be preinserted into the sleeve 466prior to deposition of the potted plant 422 into the pot cover 366. FIG.27A indicates that the sleeve 466 is opened in a manner identical tothat described for sleeving apparatus 460 in FIG. 24A. The pot cover 366is then inserted in direction 550 into the opening 474 of the sleeve466. The suction tube 468 and inflation tube 476 are retracted and thepotted plant 422 is deposited in direction 550 into a cover/sleevecombination 552 in the same manual or automatic manner as that describedpreviously. The sleeved covered potted plant 376 then is conveyed by theconveyor 378 to the boxing station 404.

[0149] The pot cover 366 may be placed manually into the sleeve 466, butin the preferred embodiment shown in FIGS. 30A-30D, a cover supplyingapparatus 364 b has a retractable cover denesting arm 554 having asuction end 556. The suction end 556 of the denesting arm 554 retrievesone of the pot covers 366 from a bin 418 a of pot covers 366 (FIG. 30A).The denesting arm 554 is retracted by a cylinder 558 to remove the potcover 366 (FIG. 30B) from the bin 418 a. The pot cover 366 istransferred to the sleeving station 372 (FIG. 30C) and is inserted intothe previously opened protective sleeve 374 (FIG. 30D). Suction isremoved from the suction end 556 therein releasing the pot cover 366.The denesting arm 554 is retracted, leaving the pot cover 366 within thesleeve 374 and in readiness for insertion of a potted plant 422 thereinusing means described herein.

Embodiment of FIGS. 31-32

[0150] Turning now to FIGS. 31 and 32, another embodiment of the articlepackaging system is designated by the reference numeral 564. The articlepackaging system 564 has stations exactly as described for articlepackaging system 350 as shown in FIGS. 22-30 and 33 except that thearticle packaging system 564 employs the same cover supplying apparatus,the same sleeving apparatus and the same boxing and closing devices forall categories of potted plants sorted at the sorting station. Theadvantage of the article packaging system 564 over the article packagingsystem 350 is that a single device performs each particular functionsuch as sleeving for all grades or categories. Since duplicateapparatuses are not required for each function, the cost and the spacerequired for the overall system is reduced.

[0151] The article packaging system 564, as shown in FIG. 31, has aplatform or table 566 serving as a servicing station 568 supporting aset of unsorted potted plants. A sorting station 570 employs a sorter(not shown) of the same type as packaging system 350 which inspectspotted plants 572 and sorts them in accordance with predeterminedcriteria such as size, quality, or variety or any of a number of othercriteria. The sorter directs each sorted potted plant 572 to either afirst parallel conveyor 574 or a second parallel conveyor 576. Pottedplants 572 of a particular category are then accumulated on the firstconveyor 574 by a restraining gate 578 or on the second conveyor 576 bya restraining gate 580 until a predetermined number of the type ofpotted plant 572 is accumulated. When the predetermined number of sortedpotted plants 572 is accumulated, the appropriate gate 578 or 580 isopened.

[0152] The potted plants 572 are then conveyed to a covering station 584where a cover supplying apparatus 586 supplies a cover 588 and whereinthe cover 588 is applied to the potted plant 572. Each covered pottedplant 590 in a particular category is then conveyed to a sleevingstation 592 where the covered potted plant 590 is deposited into asleeve (not shown) in a manner exactly as described herein for thearticle packaging system 350 and its various embodiments. Sleeved pottedplants 594 thus produced are then conveyed to a boxing station 596 suchas the boxing station 404, or its other embodiments described for system350, where the sleeved potted plants 594 are placed in cartons which arethen closed and secured for shipment.

[0153]FIG. 32 shows a version of the article packaging system 564 havinga first conveyor 600 a, a second conveyor 600 b and a third conveyor 600c which lead to the single sleeving station 592. The single sleevingstation 592 has rollers 601 and can be rolled or moved in direction 602or direction 604 between the first, second and third conveyors 600 a,600 b and 600 c manually or automatically for the purpose of supplyingsleeves 606 to potted plants 572 or covered potted plants 590 conveyedthereupon. In this way a single sleeving station 592 can supply sleeves606 to more than one of the first, second and third conveyor 600 a, 600b or 600 c and category of potted plants to reduce the cost and spacerequired for the system 564.

[0154] Alternatively, rather than having a plurality of separateconveyors such as the first, second and third conveyors 600 a-600 cconveying covered potted plants 590 to the sleeving station 592, asingle conveyor having a plurality of parallel lanes (not shown) couldbe used. Each parallel lane would have a separately regulated gate (notshown) for allowing accumulation and passage to the sleeving station 592of a predetermined number of potted plants or covered potted plants 590.

[0155] The single sleeving station indicated in FIG. 32 is shown ashaving separate conveyors 608 a-608 c for conveying the covered pottedplants 590 to the appropriate boxing station 596. Each conveyor 608a-608 c could direct the sleeved potted plants to a single conveyor (notshown) leading to a single boxing station. Alternatively, each conveyor608 a-608 c could direct the sleeved potted plants to a separate boxingstation.

[0156] As described herein for article packaging system 350, the articlepackaging system 564 could be modified in a number of ways. For example,the pot cover could be applied to the potted plant prior to accumulationon the first and second conveyors 574 or 576 by restraining gates 578 or580, respectfully; or, the pot cover could be placed into the opensleeve 606 prior to the introduction of the potted plant into the sleeve606, as indicated in the embodiment shown in FIGS. 27A-B.

Embodiment of FIG. 34

[0157] Referring now to FIG. 34, another embodiment of the articlepackaging system referred to by the reference numeral 610 isillustrated. The article packaging system 610 is constructed exactly asdescribed for article packaging systems 10, 350, or 564 or modificationsthereof except that a decorative pot cover is directly formed about theouter surface of a potted plant 612 using an appressing cover formingapparatus such as a cover forming apparatus 614 to form a covered pottedplant 616 at a point prior to application of a sleeve to the pottedplant 612. The cover forming apparatus 614 appresses a sheet of material(not shown) about the external surface of the potted plant 612 to formthe covered potted plant 616 having a cover which may or may not bebonded to the external surface of the potted plant 612, as describedherein.

[0158] The cover forming apparatus 614 which could be used, for example,is one described in U.S. Pat. No. 5,291,721 entitled “Cover FormingApparatus Having Pivoting Forming Members”, the specification of whichis hereby expressly incorporated herein. This does not exclude the useof other types of cover forming apparatuses adapted for forming a coverabout the outer surface of a potted plant to form the covered pottedplant 616.

[0159] After the potted plant 612 has been covered by the cover formingapparatus 614, the covered potted plant 616 is transferred to a conveyor618 moving in direction 620 toward a sleeving station exactly the sameas other sleeving stations previously described herein. The relocationof the covered potted plant 616 from the cover forming apparatus 614 canbe accomplished manually or automatically such as by a transfer device621 having an extendable pushing arm 622 or by some other device adaptedfor moving the covered potted plant 616 to the conveyor 618.

[0160] Changes may be made in the combinations, operations andarrangements of the various parts and elements described herein withoutdeparting from the spirit and scope of the invention as defined in thefollowing claims.

What is claimed is:
 1. A method of covering a potted plant comprising the steps of: providing a first preformed cover having an interior space; removing a second preformed cover from a set of nested preformed covers, the second preformed cover having a frustoconical shape and having an interior space; disposing the second preformed cover into the interior space of the first preformed cover; providing a potted plant; and disposing the potted plant into the interior space of the second preformed cover after the second preformed cover has been disposed within the interior space of the first preformed cover.
 2. The method of claim 1 further comprising the step of bondingly connecting the potted plant to the second preformed cover via a bonding material.
 3. The method of claim 1 wherein, in the step of providing the first preformed cover, the first preformed cover is composed of a material selected from a group of materials consisting of paper (untreated or treated in any manner), cellophane, foil, synthetic organic polymeric film, fiber (woven or nonwoven or synthetic or natural), cloth (woven or nonwoven or natural or synthetic), or burlap.
 4. The method of claim 1 wherein, in the step of providing the second preformed cover, the second preformed cover is composed of a material selected from a group of materials consisting of paper (untreated or treated in any manner), cellophane, foil, synthetic organic polymeric film, fiber (woven or nonwoven or synthetic or natural), cloth (woven or nonwoven or natural or synthetic), or burlap.
 5. A method of covering a potted plant comprising the steps of: providing a first preformed cover having an interior space; removing a second preformed cover from a set of vested preformed covers, the second preformed cover having a frustoconical shape and having an interior space; disposing the second preformed cover into the interior space of the first preformed cover; providing a potted plant; disposing the potted plant into the interior space of the second preformed cover after the second preformed cover has been disposed within the interior space of the first preformed cover; and bondingly connecting the potted plant to the second preformed cover.
 6. A method of covering a potted plant comprising the steps of: providing a first preformed cover having an interior space; removing a second preformed cover from a set of nested preformed covers, the second preformed cover having a frustoconical shape and having an interior space; disposing the second preformed cover into the interior space of the first preformed cover; providing a potted plant; disposing the potted plant into the interior space of the second preformed cover after the second preformed cover has been disposed within the interior space of the first preformed cover; and bondingly connecting the potted plant to the second preformed cover via a bonding material selected from the group consisting of adhesive or cohesive materials, heat sealable materials, sonic sealable material, vibratory sealable materials, ties, labels, bands, ribbons, string, tape, staples, or combinations thereof. 